Subaru Legacy (2005 year). Manual - part 527

4AT-89

AUTOMATIC TRANSMISSION

Transfer Clutch

5) Install the snap ring to ST.
ST

499257300

SNAP RING OUTER GUIDE

6) Install the snap ring to rear drive shaft using ST1
and ST2.
ST1

499257300

SNAP RING OUTER GUIDE

ST2

499247400

INSTALLER

7) Install the driven plate, drive plate, pressure
plate and snap ring.

8) Apply compressed air to make sure if the assem-
bled parts move smoothly.

9) Check the clearance between snap ring and
pressure gauge. <Ref. to 4AT-90, INSPECTION,
Transfer Clutch.>
10) Press-fit new ball bearing using ST.
ST

899580100

INSTALLER

11) Apply vaseline to seal ring and install to the
seal ring groove of shaft.

NOTE:
While installing the seal ring, do not expand it ex-
cessively.

(A) Snap ring

(B) Transfer clutch

(A) Snap ring

(B) Transfer clutch

(A) Snap ring

AT-00136

(A)

(B)

ST

AT-00137

(A)

(B)

ST2

ST1

AT-00138

(A)

(A) Ball bearing

(A) Seal ring

(B) Transfer clutch

AT-00139

AT-00140

(A)

ST

AT-00141

(A)

(B)

4AT-90

AUTOMATIC TRANSMISSION

Transfer Clutch

12) Install the transfer clutch assembly without
damaging seal ring.

E: INSPECTION

• Inspect the drive plate facing for wear and dam-
age.
• Make sure the snap ring is not worn and the re-
turn spring has no permanent distortion, damage,
or deformation.
• Inspect the D-ring for damage.
• Inspect the extension end play and adjust it to
within specification. <Ref. to 4AT-90, ADJUST-
MENT, Transfer Clutch.>
1) Check the clearance between snap ring and
pressure gauge.
2) Before measuring clearance, place the same
thickness of shim on both sides to prevent pressure
plate from tilting.
3) If the clearance is not within specification, adjust
it by selecting a suitable pressure plate on transfer
clutch piston side.

Initial specification:

0.7 — 1.1 mm (0.028 — 0.043 in)

Service limit:

1.6 mm (0.063 in)

4) Check that the tight corner braking phenomenon
does not occur when the vehicle is started with
steering fully turned. If tight corner braking phe-
nomenon occurs, perform the following proce-
dures.

(1) With the steering wheel held at fully turned
position, drive the vehicle in “D” range and with
vehicle speed at approx. 5 km/h (3 MPH) in both
clockwise and counterclockwise directions for
approx. ten times each, while repeating acceler-
ation and braking intermittently.
(2) If the tight corner braking phenomenon still
persists, drive the vehicle again in a circle for
several laps.

F: ADJUSTMENT

1. MP-T MODEL

1) Measure the depth “A” from the end of extension
case to the end of rear drive shaft using ST.
ST

398643600

GAUGE

2) Measure the height “B” from the transmission
case mating surface to the end of ST using ST1
and ST2.
ST1

398643600

GAUGE

ST2

499577000

GAUGE

(A) Transfer clutch

(B) Extension case

AT-00125

(A)

(B)

AT-00142

Pressure plate

Part No.

Thickness mm (in)

31593AA151

3.3 (0.130)

31593AA161

3.7 (0.146)

31593AA171

4.1 (0.161)

31593AA181

4.5 (0.177)

A

ST

AT-01029

ST2

ST1

B

AT-02210

4AT-91

AUTOMATIC TRANSMISSION

Transfer Clutch

3) Calculation formula:

NOTE:
Calculate “T”:
T = A 

− B + 35.4 mm

[T = A 

− B + 1.3937 in]

T: Thrust needle bearing thickness
A: Depth from mating surface of extension case to
end of surface of rear drive shaft ball bearing outer
race
B: Height from mating surface of transmission case
to end of ST
Example:
When A = 33.6 mm (1.3228 in), B = 65.05 mm
(2.5610 in)
T = 33.6 

− 65.05 + 35.4 = 3.95

[T = 1.3228 

− 2.5610 + 1.3937 = 0.1555]

After calculation, the value of “T” becomes 3.95,
therefore select bearing thickness of 3.8 mm (0.150
in).

NOTE:
Calculation formula for “T” is applied when measur-
ing using ST (398643600 GAUGE, 499577000
GAUGE). When not using the ST,
T = (A 

− α + 0.45 mm) − (B − β) − H

[T = (A 

− α + 0.0177 in) − (B − β) − H]

is applied.
T: Thrust needle bearing thickness
A: Depth from mating surface of extension case to
end of surface of rear drive shaft ball bearing outer
race
B: Height from mating surface of transmission case
to end of substitution as ST

α: Tool thickness used when measuring “A”

β: Tool thickness used when measuring “B”
0.45: Gasket thickness (mm)
0.0177: Gasket thickness (in)
H: Shim clearance

2. VTD MODEL

1) Insert the rear drive shaft into the reduction drive
gear and center differential assembly.

2) Using the ST, measure the depth “A”, which is
from mating surface of extension case to rear drive
shaft ball bearing outer ring contact surface.
ST

398643600

GAUGE

3) Using the ST, measure the height “B” from the
mating surface of transmission case to rear drive
shaft ball bearing.
ST

398643600

GAUGE

Thrust needle bearing

Part No.

Thickness mm (in)

806536020

3.8 (0.150)

806535030

4.0 (0.157)

806535040

4.2 (0.165)

806535050

4.4 (0.173)

806535060

4.6 (0.181)

806535070

4.8 (0.189)

806535090

5.0 (0.197)

(A) Rear drive plate

(B) Center differential carrier

AT-02211

(A)

(B)

AT-01031

ST

A

AT-01032

B

ST

4AT-92

AUTOMATIC TRANSMISSION

Transfer Clutch

4) Calculation formula:

NOTE:
Calculate “T”:
When the clearances are 0.05 mm (0.0020 in), se-
lect up to four adjusting shims from the table, suit-
able for clearance value.
When clearances are 0.05 mm (0.0020 in)
T = A 

− B + 0.40 mm

[T = A 

− B + 0.0157 in]

When clearances are 0.25 mm (0.0098 in)
T = A 

− B + 0.20 mm

[T = A 

− B + 0.0079 in]

T: Shim clearance
A: Depth from mating surface of extension case to
rear drive shaft ball bearing outer ring contact sur-
face
B: Height from mating surface of transmission case
to ball bearing end of rear drive shaft
T: Shim thickness
0.05 — 0.25 mm (0.0020 — 0.0098 in)
Example:
When A = 90.50 mm (3.5630 in), B = 90.35 mm
(3.5571 in)
Calculation when clearance is 0.05 mm (0.0020 in)
T = 90.50 

− 90.35 + 0.4 = 0.55

[T = 3.5630 

− 3.5571 + 0.0157 = 0.0216]

Calculation when clearance is 0.25 mm (0.0098 in)
T = 90.50 

− 90.35 + 0.2 = 0.35

[T = 3.5630 

− 3.5571 + 0.0079 = 0.0138]

NOTE:
Calculation formula for “T” above is applied when
measuring using ST (398643600 GAUGE). When
not using the ST,
T = (A 

− α + 0.45 mm) − (B − β) − H

[T = (A 

− α + 0.0177 in) − (B − β) − H]

is applied.
T: Thrust needle bearing thickness
A: Depth from mating surface of extension case to
rear drive shaft ball bearing outer ring contact sur-
face
B: Height from mating surface of transmission case
to rear drive shaft ball bearing end surface

α: Tool thickness used when measuring “A”

β: Tool thickness used when measuring “B”
0.45: Gasket thickness (mm)
H: Shim clearance
After calculation, the value of “T” becomes between
0.35 mm (0.0138 in) and 0.55 mm (0.0216 in),
therefore select two shims with thickness of 0.2 mm
(0.010 in) or one shim with thickness of 0.5 mm
(0.020 in).

Adjustment shim

Part No.

Thickness mm (in)

33281AA001

0.2 (0.008)

33281AA011

0.5 (0.020)